U.S. patent application number 15/331493 was filed with the patent office on 2017-05-18 for fence panel systems and methods.
The applicant listed for this patent is N. Eric Knudsen. Invention is credited to N. Eric Knudsen.
Application Number | 20170138086 15/331493 |
Document ID | / |
Family ID | 55301765 |
Filed Date | 2017-05-18 |
United States Patent
Application |
20170138086 |
Kind Code |
A1 |
Knudsen; N. Eric |
May 18, 2017 |
FENCE PANEL SYSTEMS AND METHODS
Abstract
A fence panel can include a plurality of modular fence panel
components that can be assembled modularly to form the fence panel.
The fence panel components can include a system of keys and keyways
that allow the components to interlock with one another when the
fence panel is assembled to lock the components to one another to
simplify the assembly process and to minimize the number of
mechanical fasteners needed to assemble the fence panel.
Inventors: |
Knudsen; N. Eric; (Maple
Valley, WA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Knudsen; N. Eric |
Maple Valley |
WA |
US |
|
|
Family ID: |
55301765 |
Appl. No.: |
15/331493 |
Filed: |
October 21, 2016 |
Related U.S. Patent Documents
|
|
|
|
|
|
Application
Number |
Filing Date |
Patent Number |
|
|
14705906 |
May 6, 2015 |
9506270 |
|
|
15331493 |
|
|
|
|
62037544 |
Aug 14, 2014 |
|
|
|
Current U.S.
Class: |
1/1 |
Current CPC
Class: |
E04H 17/166 20130101;
E04H 2017/1456 20130101; E04H 17/165 20130101; E04H 17/168
20130101; E04H 17/22 20130101 |
International
Class: |
E04H 17/16 20060101
E04H017/16; E04H 17/22 20060101 E04H017/22 |
Claims
1. A method of constructing a fence panel, the method comprising:
assembling a fence panel from one or more packaged arrangements of
fence panel components, the fence panel components of the fence
panel including a plurality of interior sub-panel assemblies, a
first side element, a second side element, a center rail, a bottom
rail, a top rail, a lattice divider, and a plurality of lattice
components, and the assembly of the fence panel comprising: joining
the plurality of interior sub-panel assemblies together laterally
between the first and second side elements and longitudinally
between the center rail and the bottom rail to form a panel main
body; and joining the plurality of lattice components to the panel
main body.
2. The method of claim 1 wherein joining the plurality of interior
sub-panel assemblies together laterally between the first and
second side elements and longitudinally between the center rail and
the bottom rail to form the panel main body includes fitting a
male-female mating feature of a first interior sub-panel assembly
into a male-female mating feature of a second interior sub-panel
assembly.
3. The method of claim 1 wherein joining the plurality of interior
sub-panel assemblies together laterally between the first and
second side elements and longitudinally between the center rail and
the bottom rail to form a panel main body comprises: coupling a
first end interior sub-panel assembly to the first side element and
to the bottom rail; coupling one or more intermediate interior
sub-panel assemblies to the first end interior sub-panel assembly
and the bottom rail; coupling a second end interior sub-panel
assembly to the one or more intermediate interior sub-panel
assemblies and to the bottom rail; and coupling the second side
element to the second end interior sub-panel assembly.
4. The method of claim 3, wherein joining the plurality of lattice
components to the panel main body comprises: coupling a first
lattice structure to the first side element; coupling a second
lattice structure to the second side element; and coupling the
lattice divider between the first lattice structure and the second
lattice structure.
5. The method of claim 3 wherein coupling the first end interior
sub-panel assembly to the first side element and to the bottom rail
comprises coupling a first end male-female mating feature of the
first end interior sub-panel assembly to a male-female mating
feature of the first side element and a bottom male-female mating
feature of the first end interior sub-panel assembly to a
male-female mating feature of the bottom rail.
6. The method of claim 3 wherein coupling the one or more
intermediate interior sub-panel assemblies to the first end
interior sub-panel assembly and the bottom rail comprises coupling
a plurality of interior sub-panel assemblies together in a
side-by-side arrangement.
7. The method of claim 6 wherein coupling the second end interior
sub-panel assembly to the one or more intermediate interior
sub-panel assemblies and to the bottom rail comprises coupling a
first end male-female mating feature of the second end interior
sub-panel assembly to a male-female mating feature of the one or
more intermediate interior sub-panel assemblies and a bottom
male-female mating feature of the second interior sub-panel
assembly to a male-female mating feature of the bottom rail.
8. The method of claim 3 wherein coupling the second side element
to the second end interior sub-panel assembly comprises coupling a
male-female mating feature of the second end interior sub-panel
assembly to a corresponding male-female mating feature of the
second side element.
9. The method of claim 1 wherein joining the plurality of interior
sub-panel assemblies and joining the plurality of lattice
components includes: joining the top rail to the first side
element; joining a first lattice component to the top rail and to
the first side element; joining the lattice divider to the top rail
and to the first lattice component; joining a second lattice
component to the top rail and to the lattice divider; joining the
center rail to the first side element, the first lattice component,
the lattice divider, and the second lattice component; joining a
first interior sub-panel assembly to the first side element and to
the center rail; joining a second interior sub-panel assembly to
the center rail and indirectly to the first interior sub-panel
assembly; joining the second side element to the top rail, to the
second lattice component, to the center rail, and to the second
interior sub-panel assembly; and joining the bottom rail to the
first interior sub-panel assembly, to the second interior sub-panel
assembly, to the first side element, and to the second side
element.
10. The method of claim 1 wherein joining the plurality of interior
sub-panel assemblies and joining the plurality of lattice
components includes: joining the bottom rail to the first side
element; joining a first interior sub-panel assembly to the bottom
rail and to the first side element; joining a second interior
sub-panel assembly to the bottom rail and indirectly to the first
interior sub-panel assembly; joining the center rail to the first
side element, the first interior sub-panel assembly, and to the
second interior sub-panel assembly; joining the second side element
to the bottom rail, to the second interior sub-panel assembly, and
to the center rail; joining a first lattice component to the first
side element and to the center rail; joining the lattice divider to
the center rail and to the first lattice component; joining a
second lattice component to the lattice divider, to the center
rail, and to the second side element; and joining the top rail to
the first side element, to the first lattice component, to the
lattice divider, to the second lattice component, and to the second
side element.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional application of U.S. patent
application Ser. No. 14/705,906, filed May 6, 2015, which is a
non-provisional application of U.S. Provisional Patent Application
No. 62/037,544, filed Aug. 14, 2014, both of which are hereby
incorporated herein by reference in their entireties.
BACKGROUND
[0002] Technical Field
[0003] The present disclosure relates to fences, fence panels,
modular components for forming fence panels, and related methods of
forming fence panels.
[0004] Description of the Related Art
[0005] Fences are available in a variety of designs. In some cases,
a fence can include fence posts and fence panels supported by and
spanning between adjacent fence posts. Some fence panels are opaque
structures, while others include lattice components for aesthetic
or functional purposes. Some fence panels can be assembled on-site
at an installation location, while others can be pre-fabricated and
transported to an installation location. Many currently available
fence panels are time consuming and expensive to construct, or are
too large to easily transport.
BRIEF SUMMARY
[0006] In some embodiments, a fence panel kit for constructing a
fence panel to be installed between adjacent fence posts comprises:
one or more packaged arrangements of fence panel components
including a base element, a center rail, a top rail, a first side
element, a second side element, a plurality of interior sub-panel
assemblies each including a plurality of fence boards, and at least
one lattice component, the base element, the center rail, the top
rail, the lattice divider, the first side element, the second side
element, each of the plurality of interior sub-panel assemblies,
and the at least one lattice component being disconnected from one
another for storage and transport in the one or more packaged
arrangements, and wherein the base element, the center rail, the
top rail, the first side element, the second side element, each of
the plurality of interior sub-panel assemblies, and the at least
one lattice component include interlocking features to assist in
joining the fence panel components together to form the fence
panel.
[0007] In some cases, the base element includes a bottom rail
coupled to a bottom supporting element. In some cases, the
plurality of fence boards of each of the interior sub-panel
assemblies is at least partially bordered by a plurality of
perimeter components. In some cases, the perimeter components
include interlocking features to interlock with adjoining
components. In some cases, the perimeter components of one or more
of the interior sub-panel assemblies comprises a joint member that
is configured to insertably receive a portion of an adjacent one of
the interior sub-panel assemblies when the fence panel is
constructed. In some cases, the base element, the center rail, the
top rail, the first side element, the second side element, the
plurality of interior sub-panel assemblies and a lattice divider
are packaged in a first packaged arrangement, and a plurality of
lattice components are packaged in a second packaged arrangement
separate from the first packaged arrangement.
[0008] In some cases, the lattice components are first lattice
elements having a first latticework pattern, and the fence panel
kit further comprises a third packaged arrangement of fence panel
components including a plurality of second lattice elements
disconnected from one another for storage and transport in the
third packaged arrangement, and the plurality of second lattice
elements have a second latticework pattern different from the first
latticework pattern. In some cases, the second and the third
packaged arrangements of fence panel components are alternatively
combinable with the first packaged arrangement of fence panel
components to form a complete fence panel with different lattice
structures. In some cases, the base element includes a base
male-female mating feature and each of the plurality of interior
sub-panel assemblies includes a male-female mating feature matching
the base male-female mating feature.
[0009] In some cases, the first side element includes a first side
male-female mating feature and the second side element includes a
second side male-female mating feature, the plurality of interior
sub-panel assemblies includes a first end interior sub-panel
assembly and a second end interior sub-panel assembly, the first
end interior sub-panel assembly includes a first end male-female
mating feature matching the first side male-female mating feature,
and the second end interior sub-panel assembly includes a second
end male-female mating feature matching the second side male-female
mating feature.
[0010] In some cases, the first end interior sub-panel assembly
includes an interior facing male-female mating feature and the
second end interior sub-panel assembly includes an interior facing
male-female mating feature matching the interior facing male-female
mating feature such that one or more additional interior sub-panel
assemblies with similar interlocking features can be received
between the first end interior sub-panel assembly and the second
end interior sub-panel assembly. In some cases, the fence panel
components include at least four separate interior sub-panel
assemblies arranged in a stack of interior sub-panel assemblies,
and the base element, the center rail, the top rail, a lattice
divider, the first side element, and the second side element are
positioned adjacent the stack.
[0011] In some embodiments, a method to facilitate construction of
a fence comprising a plurality of fence panels supported by fence
posts comprises: providing one or more packaged arrangements of
fence panel components including a base element, a center rail, a
top rail, a lattice divider, a first side element, a second side
element, a plurality of interior sub-panel assemblies, and a
plurality of lattice components, the base element, the center rail,
the top rail, the lattice divider, the first side element, the
second side element, each of the plurality of interior sub-panel
assemblies, and each of the plurality of lattice components being
disconnected from one another for storage and transport in the one
or more packaged arrangements, and wherein the base element, the
center rail, the top rail, the lattice divider, the first side
element, the second side element, each of the plurality of interior
sub-panel assemblies, and each of the plurality of lattice
components include interlocking features to assist in joining the
fence panel components together to form the fence panel.
[0012] In some cases, the method further comprises packaging the
base element, the center rail, the top rail, the lattice divider,
the first side element, the second side element, and the plurality
of interior sub-panel assemblies in a first packaged arrangement
and packaging the plurality of lattice components in a second
packaged arrangement separate from the first packaged arrangement.
In some cases, the method further comprises shipping the separated
first packaged arrangement and the second packaged arrangement to a
remote location for storage or use in constructing the fence
panel.
[0013] In some embodiments, a method of constructing a fence panel
comprises: assembling a fence panel from one or more packaged
arrangements of fence panel components, the fence panel components
of the fence panel including a plurality of interior sub-panel
assemblies, a first side element, a second side element, a center
rail, a bottom rail, a top rail, a lattice divider, and a plurality
of lattice components, and the assembly of the fence panel
comprising, joining the plurality of interior sub-panel assemblies
together laterally between the first and second side elements and
longitudinally between the center rail and the bottom rail to form
a panel main body, and joining the plurality of lattice components
to the panel main body.
[0014] In some cases, joining the plurality of interior sub-panel
assemblies together laterally between the first and second side
elements and longitudinally between the center rail and the bottom
rail to form the panel main body includes fitting a male-female
mating feature of a first interior sub-panel assembly into a
male-female mating feature of a second interior sub-panel assembly.
In some cases, joining the plurality of interior sub-panel
assemblies together laterally between the first and second side
elements and longitudinally between the center rail and the bottom
rail to form a panel main body comprises: coupling a first end
interior sub-panel assembly to the first side element and to the
bottom rail, coupling one or more intermediate interior sub-panel
assemblies to the first end interior sub-panel assembly and the
bottom rail, coupling a second end interior sub-panel assembly to
the one or more intermediate interior sub-panel assemblies and to
the bottom rail, and coupling the second side element to the second
end interior sub-panel assembly.
[0015] In some cases, joining the plurality of lattice components
to the panel main body comprises: coupling a first lattice
structure to the first side element, coupling a second lattice
structure to the second side element, and coupling the lattice
divider between the first lattice structure and the second lattice
structure. In some cases, coupling the first end interior sub-panel
assembly to the first side element and to the bottom rail comprises
coupling a first end male-female mating feature of the first end
interior sub-panel assembly to a male-female mating feature of the
first side element and a bottom male-female mating feature of the
first end interior sub-panel assembly to a male-female mating
feature of the bottom rail. In some cases, coupling the one or more
intermediate interior sub-panel assemblies to the first end
interior sub-panel assembly and the bottom rail comprises coupling
a plurality of interior sub-panel assemblies together in a
side-by-side arrangement.
[0016] In some cases, coupling the second end interior sub-panel
assembly to the one or more intermediate interior sub-panel
assemblies and to the bottom rail comprises coupling a first end
male-female mating feature of the second end interior sub-panel
assembly to a male-female mating feature of the one or more
intermediate interior sub-panel assemblies and a bottom male-female
mating feature of the second interior sub-panel assembly to a
male-female mating feature of the bottom rail. In some cases,
coupling the second side element to the second end interior
sub-panel assembly comprises coupling a male-female mating feature
of the second end interior sub-panel assembly to a corresponding
male-female mating feature of the second side element.
[0017] In some cases, joining the plurality of interior sub-panel
assemblies and joining the plurality of lattice components
includes: joining the top rail to the first side element, joining a
first lattice component to the top rail and to the first side
element, joining the lattice divider to the top rail and to the
first lattice component, joining a second lattice component to the
top rail and to the lattice divider, joining the center rail to the
first side element, the first lattice component, the lattice
divider, and the second lattice component, joining a first interior
sub-panel assembly to the first side element and to the center
rail, joining a second interior sub-panel assembly to the center
rail and indirectly to the first interior sub-panel assembly,
joining the second side element to the top rail, to the second
lattice component, to the center rail, and to the second interior
sub-panel assembly, and joining the bottom rail to the first
interior sub-panel assembly, to the second interior sub-panel
assembly, to the first side element, and to the second side
element.
[0018] In some cases, joining the plurality of interior sub-panel
assemblies and joining the plurality of lattice components
includes: joining the bottom rail to the first side element,
joining a first interior sub-panel assembly to the bottom rail and
to the first side element, joining a second interior sub-panel
assembly to the bottom rail and indirectly to the first interior
sub-panel assembly, joining the center rail to the first side
element, the first interior sub-panel assembly, and to the second
interior sub-panel assembly, joining the second side element to the
bottom rail, to the second interior sub-panel assembly, and to the
center rail, joining a first lattice component to the first side
element and to the center rail, joining the lattice divider to the
center rail and to the first lattice component, joining a second
lattice component to the lattice divider, to the center rail, and
to the second side element, and joining the top rail to the first
side element, to the first lattice component, to the lattice
divider, to the second lattice component, and to the second side
element.
BRIEF DESCRIPTION OF THE SEVERAL VIEWS OF THE DRAWINGS
[0019] FIG. 1 is an isometric view of a portion of a fence,
according to one example embodiment, including a plurality of fence
panels positioned between respective pairs of posts.
[0020] FIG. 2 is an isometric exploded view of a fence panel of the
fence of FIG. 1 which illustrates a plurality of fence panel
components thereof.
[0021] FIG. 2A is a cross-sectional view of a fence panel of the
fence of FIG. 1 taken along line 2A-2A.
[0022] FIG. 2B is an enlarged detail view of a portion of the
cross-sectional view of FIG. 2A.
[0023] FIG. 2C is a cross-sectional view of the fence panel of the
fence of FIG. 1 taken along line 2C-2C.
[0024] FIG. 2D is an enlarged detail view of a portion of the
cross-sectional view of FIG. 2C.
[0025] FIGS. 3A-3L illustrate one embodiment of a method of
assembling a fence panel according to a top-down assembly
methodology.
[0026] FIGS. 4A-4L illustrate another embodiment of a method of
assembling a fence panel according to a bottom-up methodology.
[0027] FIG. 5 illustrates a packaged fence panel kit, according to
one example embodiment, which includes all components for
constructing a fence panel in a single packaged arrangement.
[0028] FIGS. 5A-5F illustrate one embodiment of stacking fence
panel components to facilitate storage and transport of all
components for constructing a fence panel in a single packaged
arrangement.
[0029] FIG. 6 illustrates a packaged fence panel kit, according to
another example embodiment, which includes all components for
constructing a fence panel in a two packaged arrangements including
a base panel kit and a lattice kit.
[0030] FIG. 7 illustrates different example embodiments of fence
panel latticework patterns which may be provided in connection with
the fence panels.
DETAILED DESCRIPTION
[0031] In the following description, certain specific details are
set forth in order to provide a thorough understanding of various
disclosed embodiments. However, one skilled in the relevant art
will recognize that embodiments may be practiced without one or
more of these specific details, or with other methods, components,
materials, etc. In other instances, well-known structures,
features, devices and techniques associated with fences and fence
constructing have not been shown or described in detail to avoid
unnecessarily obscuring descriptions of the embodiments. For
example, although not illustrated in the Figures, it will be
appreciated that embodiments of the fence panels described herein
may be constructed with conventional fasteners, such as nails
and/or screws, of suitable size and quantity to form a rigid fence
structure. In addition, although example embodiments shown in the
Figures are illustrated as wood fence panels, it is appreciated
that fence panels may be formed of other materials, such as metal
or vinyl, and that aspects of the embodiments described herein may
be modified accordingly.
[0032] FIG. 1 illustrates a portion of a fence 100 and more
particularly a portion of a wood fence. Fence 100 is a completed,
assembled fence built to stand in and rise vertically from the
ground 102. In different embodiments, the fence 100 can be built in
various environments and the ground 102 can include different types
of earth, dirt, soil, rock, etc. In some embodiments, the fence 100
may be supported above the ground 102, such as, for example, by
fence post supports extending above the ground 102. Fence 100
includes a first fence panel 104, a second fence panel 106, and a
third fence panel 108 all of similar construction. Fence 100 also
includes a first fence post 110 and a second fence post 112. The
fence posts 110, 112 are positioned and supported within respective
post holes 114, 116 formed in the ground 102. The first fence panel
104 is supported at one end by the first fence post 110, the second
fence panel 106 is supported by and spans between the first fence
post 110 and the second fence post 112, and the third fence panel
108 is supported at one end by the second fence post 112. The fence
panels 104, 106, and 108 can be coupled to the fence posts 110, 112
using nails, screws, bolts, or other mechanical fasteners.
[0033] The second fence panel 106 has a length extending from a
first end of the second fence panel 106 (which is fixed to the
first fence post 110) to a second end of the second fence panel 106
(which is fixed to the second fence post 112) along a first
dimension X, which can be horizontal and aligned with the direction
in which the fence 100 runs. The second fence panel 106 also has a
height extending from a top of the second fence panel 106 to a
bottom of the second fence panel 106 along a second dimension Y,
which can be vertical and perpendicular to the first dimension X.
The second fence panel 106 also has a width extending from a first
major surface or side of the second fence panel 106 visible in FIG.
1 (e.g., a "front" of the fence panel 106) to a second major
surface or side of the second fence panel 106 not visible in FIG. 1
(e.g., a "back" or "rear" of the fence panel 106) along a third
dimension Z, which can be horizontal and perpendicular to the first
dimension X and the second dimension Y. Fence panels can have
various dimensions, such as a length of 6 feet or 8 feet, a height
of 3, 3.5, 4.0, 4.5, 5.75, or 6 feet, and a width of 0.625, 1.5,
2.5, or 3.5 inches.
[0034] FIG. 2 illustrates various components of a modular fence
panel 200 that can be used to form the fence panels 104, 106, and
108 of the fence 100 shown in FIG. 1. Fence panel 200 includes a
horizontal base element or bottom supporting element 202, a bottom
rail 204, a vertical first side element or column or post 206, a
vertical second side element or column or post 208, a first end
interior sub-panel assembly 210A, three central interior sub-panel
assemblies 210B, 210C, 210D, a second end interior sub-panel
assembly 210E, a horizontal intermediate or center crossbar or rail
212, two lattice components 214, 216, a vertical lattice divider
post 218, and an upper or top crossbar or rail 220. The first end
interior sub-panel assembly 210A, three central interior sub-panel
assemblies 210B, 210C, 210D, and second end interior sub-panel
assembly 210E can be referred to collectively as interior sub-panel
assemblies 210. The lattice components 214, 216 can each have a
first latticework pattern. Although the two lattice components 214,
216 are shown as two separate lattice assemblies separated by the
divider post 218, it is appreciated that a single latticework
assembly may be provided without the divider post 218.
[0035] The fence panel 200 can be assembled or constructed from its
various components or modules, and thus can be referred to as a
modular fence panel 200 which can be fabricated, shipped, and
assembled modularly and can make use of fence panel construction
techniques. Thus, individual components of the fence panel 200 can
be interchanged or replaced with alternative components as desired,
without the need to fabricate or obtain any additional components.
To facilitate this aspect of the modular nature of the fence panel
200, each of the components of the fence panel 200 can be provided
with complementary and interchangeable coupling elements, as
described further below. Each of the components of the fence panel
200 can have a first end (or edge), second end (or edge), top end
(or edge), bottom end (or edge), first side, and second side,
consistent with the use of those terms above with respect to FIG.
1, fence panel 106, and the dimensions X, Y, and Z.
[0036] With continued reference to FIG. 2, the horizontal base
element 202 includes a first end having a vertical key 202A
protruding therefrom and a second end having another vertical key
202B protruding therefrom. The bottom rail 204 includes a first end
having a vertical key 204A protruding therefrom and a second end
having another vertical key 204B protruding therefrom. The top of
the bottom rail 204 includes a keyway 204C extending along the
length of the bottom rail 204. The bottom rail 204 can be wider
than the base element 202 and the bottom rail 204 and base element
202 can be coupled to one another to form an elongate bottom
crossbar having a generally T-shaped cross-sectional profile. The
bottom rail 204 can be coupled to the base element 202 using
various adhesives or mechanical fasteners. The elongate bottom
crossbar may be pre-assembled or coupled together prior to receipt
by an end-user. Although a two-piece bottom crossbar is shown, a
single, unitary bottom crossbar having the same or different
cross-sectional profile may be provided in some embodiments. The
first end vertical key 202A can have dimensions matching those of
the first end vertical key 204A, and the second end vertical key
202B can have dimensions matching those of the second end vertical
key 204B, such that when the bottom rail 204 is coupled to the base
element 202, the first end vertical keys 202A, 204A have matching
profiles and form a single vertical key that can engage with a
corresponding keyway and the second end vertical keys 202B, 204B
have matching profiles and form a single vertical key that can
engage with a corresponding keyway.
[0037] With continued reference to FIG. 2, the first side element
or post 206 includes a first end having a planar face or surface
such that it can bear against and be secured to a fence post, such
as the fence posts 110, 112 shown in FIG. 1, and a second end
having a vertical keyway 206A formed therein for receiving a
complementary key (e.g., a key having a matching profile). The
first side element or post 206 also includes a top end having a
horizontal key 206B formed therein for engaging with a
complementary keyway. The second side element or post 208 includes
a first end having a vertical keyway 208A formed therein for
receiving a complementary key and a second end having a planar face
or surface such that it can bear against and be secured to a fence
post, such as the fence posts 110, 112 shown in FIG. 1. The second
side element or post 208 also includes a top end having a
horizontal key 208B formed therein for engaging with a
complementary keyway.
[0038] The first end interior sub-panel assembly 210A includes a
plurality of fence boards 222 interlocked together and partially
bordered by a first end perimeter component 224, a top perimeter
component 226, and a bottom perimeter component 228. The first end
interior sub-panel assembly 210A of the illustrated embodiment
includes five fence boards 222, including partial fence boards,
that are interlocked together, however, it is appreciated that in
other instances more or fewer fence boards 222 may be provided and
the fence boards 222 may abut each other or may be spaced apart.
The first end perimeter component 224 includes a first end having a
first end vertical key 224A formed therein for engaging with a
complementary keyway. The vertical key 224A can be complementary
with and thus can engage the keyway 206A. The top perimeter
component 226 includes a top end having a horizontal key 226A
formed therein for engaging with a complementary keyway. The bottom
perimeter component 228 includes a bottom end having a horizontal
key 228A formed therein for engaging with a complementary keyway.
The horizontal key 228A can be complementary with and thus can
engage the keyway 204C.
[0039] The first end perimeter component 224 also includes a second
end having a vertical keyway (not illustrated in FIG. 2)
complementary to a first end of one of the fence boards 222 such
that the first end of the fence board can engage with the first end
perimeter component 224, as shown best in FIG. 2D. The top
perimeter component 226 similarly includes a bottom end having a
horizontal keyway 226B complementary to top ends of the fence
boards 222 such that the top ends of the fence boards 222 can
engage with the top perimeter component 226. The bottom perimeter
component 228 similarly includes a top end having a horizontal
keyway 228B complementary to bottom ends of the fence boards 222
such that the bottom ends of the fence boards 222 can engage with
the bottom perimeter component 228.
[0040] The top perimeter component 226 also includes a first end
vertical key 226C and the bottom perimeter component 228 also
includes a first end vertical key 228C. The vertical keys 226C,
228C can both have profiles matching the first end vertical key
224A such that these three vertical keys can together form a single
vertical key of the first end interior sub-panel assembly 210A that
can engage with the keyway 206A. In one alternative embodiment, the
first end of the top perimeter component 226 can be cut flush and
have a planar surface instead of the key 226C, and the first end of
the bottom perimeter component 228 can be cut flush and have a
planar surface instead of the key 228C. The top perimeter component
226 and the bottom perimeter component 228 each extend in the
direction of the second end interior sub-panel assembly 210E a
distance beyond the fence boards 222, to accommodate a first end
perimeter component of the central interior sub-panel assembly
2106, as described in greater detail below.
[0041] With continued reference to FIG. 2, each of the central
interior sub-panel assemblies 210B, 210C, and 210D can have the
same structure to each other. Central interior sub-panel assembly
210B is described in detail herein and can be considered as
representative of the other central interior sub-panel assemblies
210C, 210D. Central interior sub-panel assembly 210B includes a
plurality of fence boards 222 interlocked together and partially
bordered by a first end perimeter component 230, a top perimeter
component 232, and a bottom perimeter component 234. The central
interior sub-panel assembly 2106 of the illustrated embodiment
includes five fence boards 222, including partial fence boards,
that are interlocked together, however, it is appreciated that in
other instances more or fewer fence boards 222 may be provided and
the fence boards 222 may abut each other or may be spaced apart.
The first end perimeter component 230 includes a first end having a
vertical keyway 230A complementary to a second end of one of the
fence boards 222 (e.g., one of the fence boards 222 of the first
end sub-panel assembly 210A) such that the second end of the fence
board 222 can engage with the first end perimeter component 230, as
shown best in FIG. 2D. The top perimeter component 232 includes a
top end having a horizontal key 232A formed therein for engaging
with a complementary keyway. The bottom perimeter component 234
includes a bottom end having a horizontal key 234A formed therein
for engaging with a complementary keyway. The horizontal key 234A
can be complementary with and thus can engage the keyway 204C.
[0042] The first end perimeter component 230 of the central
interior sub-panel assembly 210B also includes a second end having
a vertical keyway (not illustrated in FIG. 2) complementary to a
first end of one of the fence boards 222 such that the first end of
the fence board 222 can engage with the first end perimeter
component 230, as shown best in FIG. 2D. The top perimeter
component 232 also includes a bottom end having a horizontal keyway
232B complementary to top ends of the fence boards 222 such that
the top ends of the fence boards 222 can engage with the top
perimeter component 232. The bottom perimeter component 234 also
includes a top end having a horizontal keyway 234B complementary to
bottom ends of the fence boards 222 such that the bottom ends of
the fence boards 222 can engage with the bottom perimeter component
234.
[0043] As noted above, the top perimeter component 226 and the
bottom perimeter component 228 each extend in the direction of the
second end interior sub-panel assembly 210E a distance beyond the
fence boards 222, to accommodate the first end perimeter component
230 of the central interior sub-panel assembly 2106 and so that the
second ends of the top perimeter component 226 and the bottom
perimeter component 228 center on the first end perimeter component
230 of the central interior sub-panel assembly 210B. Similarly, the
top perimeter component 232 and the bottom perimeter component 234
of the central interior sub-panel assembly 2106 each extend in the
direction of the second end interior sub-panel assembly 210E a
distance beyond the fence boards 222 of the assembly 2106, to
accommodate a first end perimeter component of the central interior
sub-panel assembly 210C.
[0044] The top perimeter component 232 and the bottom perimeter
component 234 of the central interior sub-panel assembly 210B each
extend in the direction of the first end interior sub-panel
assembly 210A a distance short of the vertical keyway 230A of the
first end perimeter component 230, so that a fence board 222 of the
assembly 210A can be received in the vertical keyway 230A of the
first end perimeter component 230 of the central interior sub-panel
assembly 2106 such that the second end of the top perimeter
component 226 is generally flush with the first end of the top
perimeter component 232 and the second end of the bottom perimeter
component 228 is generally flush with the first end of the bottom
perimeter component 234.
[0045] As noted above, central interior sub-panel assemblies 210C
and 210D can have the same form or structure as the assembly 2106.
Thus, the first end perimeter component of the assembly 210C can
engage with a fence board 222 at the second end of the assembly
210B and the first end perimeter component of the assembly 210D can
engage with a fence board 222 at the second end of the assembly
210C.
[0046] The second end interior sub-panel assembly 210E includes a
plurality of fence boards 222 interlocked together and partially
bordered by a first end perimeter component 236, a top perimeter
component 238, a bottom perimeter component 240, and a second end
perimeter component 242. The second end interior sub-panel assembly
210E of the illustrated embodiment includes five fence boards 222,
including partial fence boards, that are interlocked together,
however, it is appreciated that in other instances more or fewer
fence boards 222 may be provided and the fence boards 222 may abut
each other or may be spaced apart. The second end perimeter
component 242 includes a second end having a second end vertical
key 242A formed therein for engaging with a complementary keyway.
The vertical key 242A can be complementary with and thus can engage
the keyway 208A. The top perimeter component 238 includes a top end
having a horizontal key 238A formed therein for engaging with a
complementary keyway. The bottom perimeter component 240 includes a
bottom end having a horizontal key 240A formed therein for engaging
with a complementary keyway. The horizontal key 240A can be
complementary with and thus can engage the keyway 204C. The keys
228A, 234A, 240A of the interior sub-panel assemblies 210A-210E
have matching profiles and can form a single horizontal key that is
complementary to and thus can engage with the keyway 204C of the
bottom rail 204. Although a single horizontal key may be provided,
it is also appreciated that in other instances key portions may be
intermittently spaced to collectively from the horizontal key.
[0047] The second end perimeter component 242 also includes a first
end having a vertical keyway (not illustrated in FIG. 2)
complementary to a second end of one of the fence boards 222 such
that the second end of the fence board 222 can engage with the
second end perimeter component 242. The top perimeter component 238
similarly includes a bottom end having a horizontal keyway (not
illustrated in FIG. 2) complementary to top ends of the fence
boards 222 such that the top ends of the fence boards 222 can
engage with the top perimeter component 238. The bottom perimeter
component 240 similarly includes a top end having a horizontal
keyway (not illustrated in FIG. 2) complementary to bottom ends of
the fence boards 222 such that the bottom ends of the fence boards
222 can engage with the bottom perimeter component 240.
[0048] The top perimeter component 238 also includes a second end
vertical key 238C and the bottom perimeter component 240 also
includes a second end vertical key 240C. The vertical keys 238C,
240C can both have profiles matching the second end vertical key
242A such that these three vertical keys can together form a single
vertical key of the second end interior sub-panel assembly 210E
that can engage with the keyway 208A. In one alternative
embodiment, the second end of the top perimeter component 238 can
be cut flush and have a planar surface instead of the key 238C, and
the second end of the bottom perimeter component 240 can be cut
flush and have a planar surface instead of the key 240C.
[0049] The first end perimeter component 236 includes a first end
having a vertical keyway 236A complementary to a second end of one
of the fence boards 222 (e.g., one of the fence boards 222 of the
central interior sub-panel assembly 210D) such that the second end
of the fence board 222 can engage with the first end perimeter
component 236. The first end perimeter component 230 also includes
a second end having a vertical keyway (not illustrated in FIG. 2)
complementary to a first end of one of the fence boards 222 such
that the first end of the fence board 222 can engage with the first
end perimeter component 236.
[0050] The top perimeter component 238 and the bottom perimeter
component 240 of the second end interior sub-panel assembly 210E
each extend in the direction of the first end interior sub-panel
assembly 210A a distance short of the vertical keyway 236A of the
first end perimeter component 236, so that a fence board 222 of the
assembly 210D can be received in the vertical keyway 236A of the
first end perimeter component 236 of the central interior sub-panel
assembly 210E such that the second end of the top perimeter
component of the assembly 210D is generally flush with the first
end of the top perimeter component 238 and the second end of the
bottom perimeter component of the assembly 210D is generally flush
with the first end of the bottom perimeter component 240.
[0051] With continued reference to FIG. 2, the center rail 212
includes a bottom end or bottom face having a bottom horizontal
keyway 212A formed therein and a top end or top face having a top
horizontal keyway 212B formed therein. The horizontal keys 226A,
232A, 238A can have matching profiles and can form a single
horizontal key or intermittent key portions that is/are
complementary to and thus can engage with the keyway 212A. The
center rail 212 also includes a first end having a first end key
212C formed therein and a second end having a second end key 212D
formed therein.
[0052] The vertical lattice divider post 218 includes a first end
or face having a first end keyway 218A formed therein, a second end
or face having a second end keyway 2186 formed therein, a top end
or face having a top key 218C formed therein, and a bottom end or
face having a bottom key 218D formed therein. The bottom key 218D
can be complementary to and thus can engage with the top horizontal
keyway 212B of the center rail 212.
[0053] The top rail 220 includes a bottom end having a bottom
keyway 220A formed therein, a first end having a first end planar
surface 220B, a top end having a top planar surface 220C, and a
second end having a second end planar surface 220D. When the fence
panel 200 is assembled, the first end planar surface 220B can be
generally flush with the planar surface of the first end of the
first side element or post 206 to form a flat surface that can bear
against a fence post, such as the fence posts 110, 112 shown in
FIG. 1, and the second end planar surface 220D can be generally
flush with the planar surface of the second end of the second side
element or post 208 to form a flat surface that can bear against a
fence post, such as the fence posts 110, 112 shown in FIG. 1.
[0054] The first lattice component 214 includes a first end
perimeter element 244 having a first end key 244A formed therein, a
second end perimeter element 246 having a second end key 246A
formed therein, a top end perimeter element 248 having a top key
248A formed therein, a bottom end perimeter element 250 having a
bottom key 250A formed therein, and latticework extending between
the first end, second end, top, and bottom elements 244, 246, 248,
and 250. Similarly, the second lattice component 216 includes a
first end perimeter element 252 having a first end key 252A formed
therein, a second end perimeter element 254 having a second end key
254A formed therein, a top end perimeter element 256 having a top
key 256A formed therein, a bottom end perimeter element 258 having
a bottom key 258A formed therein, and latticework extending between
the first end, second end, top, and bottom elements 252, 254, 256,
258.
[0055] The keys 250A, 218D, 258A have matching profiles and can
form a single horizontal key or intermittent key portions that
is/are complementary to and thus can engage with the keyway 212B of
the center rail 212. The second end key 246A of the first lattice
component 214 can be complementary to the first end keyway 218A of
the divider post 218 and the first end key 252A of the second
lattice component 216 can be complementary to the second end keyway
218B of the divider post 218. The keys 248A, 218C, 256A have
matching profiles that also match the profiles of the key 206B of
the first side element or post 206 and the key 208B of the second
side element or post 208, such that the keys 248A, 218C, 256A,
206B, and 208B can form a single horizontal key or intermittent key
portions that is/are complementary to and thus can engage with the
keyway 220A of the top rail 220.
[0056] The keys 202A, 204A, 228C, 224A, 226C, 212C, 244A have
matching profiles and can form a single vertical key or
intermittent key portions that is/are complementary to and thus can
engage with the keyway 206A of the first side element or post 206.
The keys 202B, 204B, 240C, 242A, 238C, 212D, and 254A have matching
profiles and can form a single vertical key or intermittent key
portions that is/are complementary to and thus can engage with the
keyway 208A of the second side element or post 208.
[0057] In some embodiments, fence posts such as fence posts 110 and
112 can be provided with keys and keyways to engage with respective
keys and keyways of the components of a fence panel such as fence
panel 200. In such embodiments, the fence panel can be provided
without side elements or posts such as side elements or posts 206
and 208, and the sub-panel assemblies 210 can be coupled directly
to the fence posts 110, 112.
[0058] FIG. 2A illustrates a cross sectional profile of the fully
assembled fence panel 200 taken along line 2A-2A shown in FIG. 1.
FIG. 2B illustrates a portion of FIG. 2A at a larger scale. FIG. 2C
illustrates a cross sectional profile of the fully assembled fence
panel 200 taken along line 2C-2C shown in FIG. 1. FIG. 2D
illustrates a portion of FIG. 2C at a larger scale. As illustrated
in FIG. 2D, the fence boards 222 can have a first end including a
key 274 and a second end including a keyway 276 complementary to
the key 274. When the interior sub-panel assemblies 210 are
assembled, the keys 274 of the fence boards 222 can be engaged with
corresponding keyways 276 of adjacent fence boards 222. Thus, the
fence boards 222 of an interior sub-panel assembly 210 can be
interlocked with one another. In other instances, the fence boards
222 may lack the aforementioned keys 274 and keyways 276 and may
have flat or blunt ends that may abut each other or may be spaced
apart.
[0059] Any paired key and keyway that are complementary to one
another such that they can fit together and engage with one another
can allow the key to fit snugly or with some pre-selected
clearance, or be received, within the corresponding keyway. The
keys and keyways described herein are interlocking features that
can assist in joining the various fence panel components together.
The keys and keyways described herein can in some embodiments be
tongues and grooves or tenons and mortises, and they can include
surfaces that can interlock with one another. The keys and keyways
described herein can have the same, similar, or different shapes as
one another. The components of fence panel 200 are described as
having keys and keyways in certain locations, though the locations
can be modified as desired. In one simple modification, the
locations of any keyway and its corresponding key(s) can be
reversed. In some cases, the keys and keyways described herein can
be referred to as first and second male-female mating features,
where a first male-female mating feature can be a key and a
complementary second male-female mating feature can be a
complementary keyway, or a first male-female mating feature can be
a keyway and a complementary second male-female mating feature can
be a complementary key.
[0060] In some embodiments, many of the keys described herein can
have the same structure, or matching profiles, as one another, such
that the keys are standardized and interchangeable with one
another. Similarly, many of the keyways described herein can have
the same structure, or matching profiles, as one another, such that
the keyways are standardized and interchangeable with one another.
In such embodiments, manufacturing costs can be reduced and various
components can be interchanged and re-arranged as desired. In some
cases, the keys and keyways described herein can include recesses
for receiving the heads of screws, nails, or other fasteners, and
can include gap regions or other features for receiving glue or
other adhesives, thereby allowing efficient installation and
minimal seepage and expansion of the various components, such as
seepage of an adhesive outside of a keyway.
[0061] FIGS. 3A through 3L illustrate one possible method of
assembling a fence panel such as fence panel 200 via a top-down
methodology. In the method illustrated in FIGS. 3A through 3L, the
various components can be coupled or joined to one another in
various ways, such as by using mechanical fasteners such as nails,
screws, or bolts, or by using adhesives such as glue, such as glue
rated for outdoor use, moisture activated PUR, epoxy, etc. Two
components can be directly coupled or joined to one another, such
that they are in direct contact, or can be indirectly coupled to
one another, such that one or more other components are located
between the two components. The top-down methodology illustrated in
FIGS. 3A through 3L can be advantageous at least because it allows
the user to obtain a relatively tight fit of the components at the
top of the fence panel 200.
[0062] In FIG. 3A, the second side element or post 208 can be
coupled to the top rail 220 to form a partially assembled fence
panel, illustrated lying on the ground in FIG. 3A. For example, the
key 208B can be engaged with the keyway 220A, and screws can be
used to secure the second side element or post 208 to the top rail
220. In FIG. 3B, the partially assembled fence panel can be stood
upright and the second lattice component 216 can be coupled to the
top rail 220 and the second side element or post 208. For example,
the key 256A can be engaged with the keyway 220A and the key 254A
can be engaged with the keyway 208A.
[0063] In FIG. 3C, the divider post 218 can be coupled to the top
rail 220 and to the second lattice component 216. For example, the
key 218C can be engaged with the keyway 220A, the key 252A can be
engaged with the keyway 218B, and screws can be used to secure the
divider post 218 to the top rail 220. In FIG. 3D, the first lattice
component 214 can be coupled to the top rail 220 and to the divider
post 218. For example, the key 246A can be engaged with the keyway
218A and the key 248A can be engaged with the keyway 220A. In FIG.
3E, the center rail 212 can be coupled to the second side element
or post 208, the second lattice component 216, the divider post
218, and the first lattice component 214. For example, the key 212D
can be engaged with the keyway 208A, the keys 258A, 218D, 250A can
be engaged with the keyway 212B, and screws can be used to secure
the center rail 212 to the divider post 218 and to the second side
element or post 208.
[0064] In FIG. 3F, the second end interior sub-panel assembly 210E
can be coupled to the second side element or post 208 and to the
center rail 212. For example, the key 242A can be engaged with the
keyway 208A and the key 238A can be engaged with the keyway 212A.
In FIG. 3G, the central interior sub-panel assembly 210D can be
coupled to the second end interior sub-panel assembly 210E and to
the center rail 212. For example, a fence board 222 of the assembly
210D can be engaged with the keyway 236A and the key 232A of the
assembly 210D can be engaged with the keyway 212A. In FIG. 3H, the
central interior sub-panel assembly 210C can be coupled to the
central interior sub-panel assembly 210D and to the center rail
212. For example, a fence board 222 of the assembly 210C can be
engaged with the keyway 230A of the assembly 210D and the key 232A
of the assembly 210C can be engaged with the keyway 212A. In FIG.
3I, the central interior sub-panel assembly 210B can be coupled to
the central interior sub-panel assembly 210C and to the center rail
212. For example, a fence board 222 of the assembly 2106 can be
engaged with the keyway 230A of the assembly 210C and the key 232A
of the assembly 2106 can be engaged with the keyway 212A. In FIG.
3J, the first end interior sub-panel assembly 210A can be coupled
to the central interior sub-panel assembly 2106 and to the center
rail 212. For example, a fence board 222 of the assembly 210A can
be engaged with the keyway 230A of the assembly 2106 and the key
226A of the assembly 210A can be engaged with the keyway 212A.
[0065] In FIG. 3K, the first side element or post 206 can be
coupled to the top rail 220, the first lattice component 214, the
center rail 212, and the first end interior sub-panel assembly
210A. For example, the key 206B can be engaged with the keyway
220A, the keys 244A, 212C, 226C, 224A, and 228C can be engaged with
the keyway 206A, and screws can be used to secure the first side
element or post 206 to the top rail 220 and to the center rail 212.
In FIG. 3L, the base element 202 can be coupled to the bottom rail
204 (e.g., using screws) to form the elongate bottom crossbar, and
the elongate bottom crossbar can be coupled to the first side
element or post 206, the second side element or post 208, and the
sub-panel assemblies 210A-210E. For example, the keys 202A and 204A
can be engaged with the keyway 206A, the keys 202B and 204B can be
engaged with the keyway 208A, the keys 228A, 234A, and 240A of the
sub-panel assemblies 210A-210E can be engaged with the keyway 204C,
and screws can be used to secure the elongate bottom crossbar to
the second side element or post 208 and to the first side element
or post 206.
[0066] In the method illustrated in FIGS. 3A to 3L, each of the
sub-panel assemblies 210 and each of the lattice components 214,
216 can be pre-assembled. That is, the components of each sub-panel
assembly 210 and each lattice component 214, 216 can be secured to
one another prior to packaging the sub-panel assembly for storage
or shipment. In alternative embodiments, however, these components
can come disassembled instead of pre-assembled. The elongate bottom
crossbar may be pre-assembled or coupled together prior to receipt
by an end-user. Although a two-piece bottom crossbar is shown, a
single, unitary bottom crossbar having the same or different
cross-sectional profile may be provided in some embodiments.
[0067] In the method illustrated in FIGS. 3A to 3L, the base
element 202, bottom rail 204, top rail 220, second side element or
post 208, divider post 218, first side element or post 206, lattice
components 214, 216, center rail 212, and sub-panel assemblies
210A-210E can be disconnected from one another when packaged for
storage and shipment. That is, no mechanical fasteners or adhesives
can fasten or affix these components to one another when they are
packaged for storage or shipment.
[0068] As described above, screws or other fasteners can be used to
secure (i.e., fasten or directly couple) the second side element or
post 208, top rail 220, divider post 218, center rail 212, first
side element or post 206, base element 202, and the bottom rail 204
to one another. In some embodiments, the pilot holes 260 shown in
FIG. 2 or indentations or depressions indicating fastener locations
can be provided in these components prior to packaging for storage
and assembly to facilitate the use of screws or other fasteners in
this way during assembly of the fence panel 200. In some
embodiments, screws (or alternate fasteners) can be the only
mechanism fastening the components of the fence panel 200 to one
another. That is, the sub-panel assemblies 210 and the lattice
components 214, 216 can be secured to the other components of the
fence panel 200 only by way of the keys and keyways of the
components of the fence panel 200. That is, they can be held
captive within the completely assembled fence panel 200 by the keys
and keyways of the various components of the fence panel 200. Thus,
the fence panel 200 can be assembled, for example at an
installation location, using a minimal number of mechanical
fasteners and no adhesives, minimizing material costs and time
required to assemble the fence panel 200.
[0069] FIGS. 4A to 4L illustrate another possible method of
assembling a fence panel such as fence panel 200 via a bottom-up
methodology. In the method illustrated in FIGS. 4A to 4L, the
various components can be coupled to one another in various ways,
such as by using mechanical fasteners such as nails, screws, or
bolts, or by using adhesives such as glue, epoxy, etc. In FIG. 4A,
the base element 202 can be coupled to the bottom rail 204 (e.g.,
using screws) to form the elongate bottom crossbar, and the first
side element or post 206 can be coupled to the elongate bottom
crossbar to form a partially assembled fence panel. For example,
the keys 202A, 204A can be engaged with the keyway 206A, and screws
can be used to secure the first side element or post 206 to the
elongate bottom crossbar.
[0070] In FIG. 4B, the first end interior sub-panel assembly 210A
can be coupled to the first side element or post 206 and to the
elongate bottom crossbar. For example, the key 224A can be engaged
with the keyway 206A and the key 228A can be engaged with the
keyway 204C. In FIG. 4C, the central interior sub-panel assembly
210B can be coupled to the first end interior sub-panel assembly
210A and to the elongate bottom crossbar. For example, a fence
board 222 of the assembly 210A can be engaged with the keyway 230A
and the key 234A of the assembly 210B can be engaged with the
keyway 204C. In FIG. 4D, the central interior sub-panel assembly
210C can be coupled to the central interior sub-panel assembly 210B
and to the elongate bottom crossbar. For example, a fence board 222
of the assembly 210B can be engaged with the keyway 230A of the
assembly 210C and the key 234A of the assembly 210C can be engaged
with the keyway 204C. In FIG. 4E, the central interior sub-panel
assembly 210D can be coupled to the central interior sub-panel
assembly 210C and to the elongate bottom crossbar. For example, a
fence board 222 of the assembly 210C can be engaged with the keyway
230A of the assembly 210D and the key 234A of the assembly 210D can
be engaged with the keyway 204C. In FIG. 4F, the second end
interior sub-panel assembly 210E can be coupled to the central
interior sub-panel assembly 210D and to elongate bottom crossbar.
For example, a fence board 222 of the assembly 210D can be engaged
with the keyway 236A of the assembly 210E and the key 240A of the
assembly 210E can be engaged with the keyway 204C.
[0071] In FIG. 4G, the center rail 212 can be coupled to the first
side element or post 206 and to the sub-panel assemblies 210A-210E.
For example, the key 212C can be engaged with the keyway 206A, the
keys 226A, 232A, and 238A of the assemblies 210A-210E can be
engaged with the keyway 212A, and screws can be used to secure the
first side element or post 206 to the center rail 212. In FIG. 4H,
the second side element or post 208 can be coupled to the elongate
bottom crossbar, the second end interior sub-panel assembly 210E,
and to the center rail 212. For example, the keys 202B, 204B, 242A,
and 212D can be engaged with the keyway 208A and screws can be used
to secure the second side element or post 208 to the elongate
bottom crossbar and to the center rail 212. In FIG. 4I, the first
lattice component 214 can be coupled to the center rail 212 and to
the first side element or post 206. For example, the key 244A can
be engaged with the keyway 206A and the key 250A can be engaged
with the keyway 212B.
[0072] In FIG. 4J, the divider post 218 can be coupled to the
center rail 212 and to the first lattice component 214. For
example, the key 246A can be engaged with the keyway 218A, the key
218D can be engaged with the keyway 212B, and screws can be used to
secure the divider post 218 to the center rail 212. In FIG. 4K, the
second lattice component 216 can be coupled to the center rail 212
and to the divider post 218. For example, the key 228A can be
engaged with the keyway 212B and the key 252A can be engaged with
the keyway 218B. In FIG. 4L, the top rail 220 can be coupled to the
first side element or post 206, the first lattice component 214,
the divider post 218, the second lattice component 216, and the
second side element or post 208. For example, the keys 206B, 248A,
218C, 256A, and 208B can be engaged with the keyway 220A and screws
can be used to secure the top rail 220 to the first side element or
post 206, divider post 218, and second side element or post
208.
[0073] In the method illustrated in FIGS. 4A to 4L, each of the
sub-panel assemblies 210 and each of the lattice components 214,
216, can be pre-assembled. That is, the components of each
sub-panel assembly 210 and each lattice component 214, 216, can be
secured to one another prior to packaging the sub-panel assembly
for storage or shipment. In alternative embodiments, however, these
components can come disassembled instead of pre-assembled. The
elongate bottom crossbar may be pre-assembled or coupled together
prior to receipt by an end-user. Although a two-piece bottom
crossbar is shown, a single, unitary bottom crossbar having the
same or different cross-sectional profile may be provided in some
embodiments.
[0074] In the method illustrated in FIGS. 4A to 4L, the base
element 202, bottom rail 204, top rail 220, second side element or
post 208, divider post 218, first side element or post 206, lattice
components 214, 216, center rail 212, and sub-panel assemblies
210A-210E, can be disconnected from one another when packaged for
storage and shipment. That is, no mechanical fasteners or adhesives
can fasten or affix these components to one another when they are
packaged for storage or shipment.
[0075] The components of a fence panel such as fence panel 200 can
be referred to collectively as a fence panel kit. A fence panel kit
can be packaged in various ways for storage and transportation from
a manufacturing or packaging location to an installation location
or other location, such as, for example, home improvement and
hardware stores for sale to individual consumers, contractors,
fence builders or others. FIG. 5 illustrates that in some
embodiments, a fence panel kit 300 can include a plurality of fence
panel components 302 packaged within external packaging 304 such as
cardboard or plastic to form a single packaged arrangement 306 of
fence panel components 302. In some embodiments, the fence panel
components 302 include the base element 202, bottom rail 204, first
side element or post 206, second side element or post 208,
sub-panel assemblies 210, center rail 212, lattice components 214,
216, divider post 218, and top rail 220, and each of these
components 302 can be disconnected from one another in the single
packaged arrangement 306 of the kit 300. Fasteners may also be
included such that an entirety of a fence panel can be constructed
or erected from the single packaged arrangement 306.
[0076] FIGS. 5A through 5F illustrate one method of efficiently
stacking the fence panel components 302 for packaging within the
external packaging 304. In particular, FIG. 5A illustrates that
many of the components, including the base element 202, bottom rail
204, first side element or post 206, second side element or post
208, center rail 212, divider post 218, and top rail 220 can be
positioned in a first, bottom layer 330 with these components
generally aligned longitudinally in a side-by-side manner, and the
first and second lattice components 214, 216 can be positioned in a
second layer stacked on top of the first layer. FIG. 5B illustrates
that the second end interior sub-panel assembly 210E can be
positioned in a third layer stacked on top of the second layer.
[0077] FIG. 5C illustrates that the central interior sub-panel
assembly 210D can be positioned in a fourth layer stacked on top of
the third layer, such that the first end perimeter component 230 of
the sub-panel assembly 210D is positioned at a first side of the
stack of the components 302. FIG. 5D illustrates that the central
interior sub-panel assembly 210C can be positioned in a fifth layer
stacked on top of the fourth layer, such that the first end
perimeter component 230 of the sub-panel assembly 210C is
positioned at a second side, opposite to the first side, of the
stack of the components 302, such that the bottom perimeter
component 234 of the assembly 210C is adjacent to and offset from
the top perimeter component 232 of the assembly 210D, and such that
the top perimeter component 232 of the assembly 210C is adjacent to
and offset from the bottom perimeter component 234 of the assembly
210D.
[0078] FIG. 5E illustrates that the central interior sub-panel
assembly 210B can be positioned in a sixth layer stacked on top of
the fifth layer, such that the first end perimeter component 230 of
the sub-panel assembly 210B is positioned at the first side of the
stack of the components 302, such that the bottom perimeter
component 234 of the assembly 2106 is adjacent to and offset from
the top perimeter component 232 of the assembly 210C, and such that
the top perimeter component 232 of the assembly 2106 is adjacent to
and offset from the bottom perimeter component 234 of the assembly
210C. FIG. 5F illustrates that the first end interior sub-panel
assembly 210A can be positioned in a seventh layer stacked on top
of the sixth layer, such that the first end perimeter component 224
of the sub-panel assembly 210A is positioned at the second side of
the stack of the components 302, such that the bottom perimeter
component 228 of the assembly 210A is adjacent to and offset from
the top perimeter component 232 of the assembly 2106, and such that
the top perimeter component 226 of the assembly 210A is adjacent to
and offset from the bottom perimeter component 234 of the assembly
210B.
[0079] Thus, the fence panel components 302 can be stacked in a
nested configuration with each assembly 210 interlaid with the
adjacent assemblies 210 such that the orientations of the
assemblies 210 alternate within the stack of the components 302.
This nested stacking configuration can be particularly efficient,
and can allow the stack of fence panel components 302 for
constructing a fence panel having overall dimensions of about 72
inches wide by 72 inches tall to have a height of about 9 inches or
less than 10 inches, a width of about 16 inches or less than 17
inches, and a length of about 72 inches or less than 73 inches, and
be packaged in a single box or external packaging 304 having a
height of about 9 inches or less than 10 inches, a width of about
16 inches or less than 17 inches (e.g., 16.25 inches), and a length
of about 72 inches or less than or equal to 73 inches.
[0080] FIG. 6 illustrates that in other embodiments, a fence panel
kit 310 can include a plurality of fence panel components 312
packaged within external packaging 314 such as metallic or plastic
bands wrapped around the components 312 to hold them against one
another to form a first packaged arrangement 316 of fence panel
components 312. In some embodiments, the fence panel components 312
include the components of a main body of a fence panel, that is,
the base element 202, bottom rail 204, first side element or post
206, second side element or post 208, sub-panel assemblies 210,
center rail 212, divider post 218, and the top rail 220, as well as
the fasteners such as screws that allow the components to be
fastened to one another, and each of these components 312 can be
disconnected from one another in the first packaged arrangement 316
of the kit 310. The first packaged arrangement 316 can be referred
to as a main body packaged arrangement 316.
[0081] The fence panel kit 310 can also include a plurality of
fence panel components 318 packaged within external packaging 320
such as metallic or plastic bands wrapped around the components 318
to hold them against one another to form a second packaged
arrangement 322 of fence panel components 318. In some embodiments,
the fence panel components 318 include the first and second lattice
components 214, 216, and each of these components 318 can be
disconnected from one another in the second packaged arrangement
322 of the kit 310. The second packaged arrangement 322 can be
referred to as a lattice packaged arrangement. In such embodiments,
a consumer (e.g., individual homeowner, contractor, fence builder,
etc.) can purchase a main body packaged arrangement, and can select
a lattice packaged arrangement from a plurality of different
lattice packaged arrangements based on their preference for
latticework patterns. Additional lattice components having
different latticework patterns, such as copper lattice, solid slate
filling in the lattice area, stamped tin lattice components, and
lattice components having engraved figures such as stars, fish,
etc. can also be made available for purchase by the consumer. Some
examples of alternate lattice components are shown in FIG. 7.
[0082] FIG. 6 illustrates a first configuration of the main body
packaged arrangement 316 that includes a stack of the sub-panel
assemblies 210 stacked on top of the base element 202, bottom rail
204, first side element or post 206, second side element or post
208, center rail 212, and top rail 220. The divider post 218 can be
adjacent to the stack of sub-panel assemblies 210 on top of the
rest of the components 312. In a second possible configuration,
however, at least two sub-panel assemblies 210 are stacked on one
another in a first stack, at least two sub-panel assemblies 210 are
stacked on one another in a second stack, the first stack and the
second stack are longitudinally adjacent to one another, and the
first stack and the second stack are positioned on top of the rest
of the components of the main body packaged arrangement 316. In
such a configuration, the rest of the components of the main body
packaged arrangement 316 span across and hold the first and second
stacks together.
[0083] Both of these configurations of the main body packaged
arrangement are compact and space-efficient. In particular, a main
body packaged arrangement 316 having the second configuration can
have overall dimensions of about 99'' by about 16'' by about 6'',
and can weigh about 65 lbs. or less. The lattice packaged
arrangement can have overall dimensions of about 47'' by about 13''
by about 3'', and can weigh about 13 lbs. or less. A complete fence
panel having a height of about 69'' and a length of about 72'' can
be assembled from these two packaged arrangements of fence panel
components.
[0084] As explained above, the lattice components 214, 216 each
have a first latticework pattern. FIG. 7 illustrates that fence
panels can include various other lattice components that have
various other latticework patterns. The components of the fence
panels described herein other than the lattice components, e.g.,
the base element 202, bottom rail 204, first side element or post
206, second side element or post 208, sub-panel assemblies 210,
center rail 212, divider post 218, and top rail 220, can be
referred to collectively as a main body of the fence panel when
assembled, and various different lattice components can be provided
and can be interchangeably combined with the main body to form a
fully assembled fence panel.
[0085] For example, FIG. 7 illustrates that some lattice components
262, 264 can have a generally diagonal latticework pattern that is
different from the latticework pattern shown in FIG. 1 and can be
combined with a fence panel main body to form a fully assembled
fence panel. As another example, FIG. 7 illustrates that some
lattice components 266, 268 can have a generally horizontal and
vertical latticework pattern that is different from the
aforementioned latticework patterns and can be combined with a
fence panel main body to form a fully assembled fence panel. As yet
another example, FIG. 7 illustrates that lattice components 270,
272 can have a solid latticework pattern that is still yet
different from the other illustrated latticework patterns and can
be combined with a fence panel main body to form a fully assembled
fence panel.
[0086] FIG. 7 illustrates that individual components of the fence
panels described herein (e.g., the lattice components) can be
interchanged or replaced with alternative components as desired,
without the need to fabricate or obtain any additional components.
FIG. 7 illustrates that the lattice components are interchangeable
or replaceable, although all of the components of the fence panels
described herein are similarly interchangeable or replaceable. For
example, the sub-panel assemblies 210 can be replaced with
sub-panel assemblies of another style or design. In some cases, the
sub-panel assemblies 210 can be replaced with interior lattice
elements having a latticework pattern matching the latticework
pattern of one of the lattice elements described herein.
[0087] In some embodiments, any of the fence panels described
herein can include a cable or wire such as a 1/8'' galvanized wire
rope coupled to and spanning between the first side post and the
second side post to provide tension between the side posts, such as
to add lateral wind load stability for longer fence panels such as
96'' long fence panels. In some cases, the cable can be coupled to
the first and second side posts using threaded bolts, which can be
turned to adjust the tension in the cable. In some cases,
additional coupling elements such as clips can be used to
structurally tie the cable to an interior portion of the fence
panel to reduce frictional wear of the fence panel caused by motion
of the cable. Such an embodiment can be used to provide additional
wind strength if desired in high wind load areas.
[0088] Any of the fence panel components described herein can be
fabricated from any suitable material or materials, such as various
wood materials, plastic materials, vinyl, or metal materials. The
fence panels and fence panel components described herein can have
any suitable dimensions. The fence panels described herein can have
any number of lattice components and any number of interior
sub-panel assemblies. For example, a fence panel can have two
lattice components and five interior sub-panel assemblies. In other
embodiments, a fence panel can have 1, 3, 4, 5, 6, or more lattice
components, and the fence panel can have 1, 2, 3, 4, 6, 7, 8, 9,
10, or more interior sub-panel assemblies.
[0089] Moreover, the various embodiments described above can be
combined to provide further embodiments. U.S. provisional patent
application No. 62/037,544 is incorporated herein by reference, in
its entirety. Aspects of the embodiments described herein can be
combined with any additional aspects shown or described in the '544
application to provide yet further embodiments.
[0090] These and other changes can be made to the embodiments in
light of the above-detailed description. In general, in the
following claims, the terms used should not be construed to limit
the claims to the specific embodiments disclosed in the
specification and the claims, but should be construed to include
all possible embodiments along with the full scope of equivalents
to which such claims are entitled. Accordingly, the claims are not
limited by the disclosure.
* * * * *